Outdoor Sunshade

ABSTRACT

The present disclosure is for an outdoor sunshade. The outdoor sunshade comprises a tent frame and a roof, wherein the roof comprises a central roof located in the middle and a surrounding roof encompassing and below the central roof such that a vertical gap exists between the central roof and the surrounding roof. The central roof is supported by one or more upper frames while the surrounding roof is supported by one or more lower frames. Each upper frame supports a first coupler and each lower frame supports a second coupler where each first coupler is designed to releasably mate with each second coupler. By mating the first coupler to the second coupler, the upper frame and lower frame are joined together, becoming a single piece supporting both the central roof and the surrounding roof. As first coupler and second coupler may be releasably mated and unmated with each other, the packaging and transportation costs are reduced, and the firmness and bearing capacity of the outdoor sunshade are ensured at the same time.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from Chinese application number 2021228916777 filed on Nov. 24, 2021. The entire disclosure of the prior application is considered to be part of the disclosure of the accompanying application and is hereby incorporated by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention is in the field of roof structures for outdoor sunshade structures such as gazebos, rotundas, arbors, kiosks, bandstands, and sheds. All these structures and other related structures will be referred to as gazebos hereafter. More particularly, the present invention is a unique interconnecting roof support system that allows for the construction of two-tier roof structures while at the same time minimizing packaging and shipping costs. Accordingly, the present disclosure makes specific reference to the unique interconnecting roof support system thereto. However, it is to be appreciated that aspects of the present invention are also equally amenable to other like applications, devices, and methods of manufacture.

2. Description of the Related Art

Gazebos are widely used in leisure places such as backyards, squares, beaches, parks, courtyards, and more. Gazebos provide people with a comfortable leisure and cooling space away from direct sunlight or rain and may be built by craftsmen on-site or shipped as parts and assembled on-site. When shipped as parts, the packaging and shipping costs are considerable and care must be taken to ensure that packaging and shipping costs are kept to a minimum.

Additionally, gazebos that utilize a two-tier roof structure are desirable and aesthetically pleasing. Such designs are less susceptible to high wind weather conditions because of the gap that exists between the upper and lower roof tiers. This gap becomes ever more important as over time the square footage of gazebos desired by consumers has grown. However, due to the increased length of the frame to support such a roof structure along its hips, packaging and shipping costs for the gazebo have increased as well as increased structural demands on the frame supporting the hip.

A gazebo that utilizes a frame to support a roof's hip is found in U.S. patent publication 2022/0081900 to Meether et al. In Meether, the main support beam 40 and four lateral beams 42 are used to support the roof's hip. However, in Meether, the roof structure is single-tier and thus more susceptible to sustaining damage from high winds. Moreover, as the square footage of the roof structure increases, so will the length of the main support beam 40 and four lateral beams 42. As the size of the Meether gazebo grows, so will the packaging and shipping costs along with the structural demands on the main support beam 40 and the four lateral beams 42.

A gazebo that utilizes a frame to support a two-tier roof structure is found in U.S. Pat. No. 10,184,264 to Hunt et al. Here Hunt discloses a roof support structure comprised of one or more roof frame member 152. Each roof frame member includes a pair of generally parallel, spaced apart lower and upper tubular members 154 and 156. The lower tubular member 154 supports the larger and lower first roof tier. The short upper tubular member 156 is used to support the smaller and upper second roof tier. The pair of tubular members 154 and 156 are connected to one another by two spaced apart tubular members 158, which are each disposed generally perpendicular to each of the lower and upper tubular members 154 and 156. The tubular members 158 form the gap that allows for the venting of excess air. However, as one may realize, roof frame member 152 is a very long piece. This results in greater costs when packaging and shipping such a lengthy piece. In addition, the greater structural demands on roof frame member 152 will result in higher manufacturing costs.

It is desirable to utilize a roof supporting system for a gazebo that may be easily assembled together and packaged in smaller containers to be shipped to the construction site yet provides the structural integrity to support a roof during adverse weather conditions such as wind, rain, or snow.

BRIEF SUMMARY OF THE INVENTION

The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed invention. This summary is not an extensive overview, and it is not intended to identify key or critical elements or to delineate the scope thereof. Its sole purpose is to present some general concepts in a simplified form as a prelude to the more detailed description that is presented later.

The purpose of this disclosure is to reveal a novel assembly to support the hips of a two-tier gazebo roof structure that may be used to solve the above-mentioned technical problems, realize the disassembly and assembly of components, reduce the cost of packaging and transportation, and at the same time ensure the firmness and bearing capacity of the product structure.

The gazebo of the present disclosure comprises a tent frame and a roof, wherein the roof comprises a central roof located in the middle of the roof and a surrounding roof encompassing and below the central roof such that a vertical gap exists between the central roof and the surrounding roof. The central roof is supported by one or more upper frames while the surrounding roof is supported by one or more lower frames. Each upper frame has attached, by welding or other similar means, a first coupler. Each lower frame has attached, by welding or other similar means, a second coupler. Each first coupler is designed to releasably mate with each second coupler. By mating first coupler to second coupler, upper frame and lower frame are joined together becoming one piece supporting both the central roof and the surrounding roof.

To mate first coupler with second coupler, the first coupler includes a first seat and a first body, the first seat and the first body are arranged in an “L” shape where the first seat is the horizontal portion of the “L” and the first body is the vertical portion of the “L”. Within the first body is found first cavity and within first cavity there are at least two first guides. Each first guide contains a through hole with a counterbore at both ends of the through hole. The second coupler includes a second seat and a second body, the second seat and the second body are arranged in an “L” shape where the second seat is the horizontal portion of the “L” and the second body is the vertical portion of the “L”. Within the second body is found second cavity and within second cavity there are at least two second guides. Each second guide contains a blind hole having a ridge surrounding the blind hole. The ridge surrounding the blind hole of second guide is so designed to fit within the counterbore surrounding the through hole of first guide so as to mate first coupler with second coupler.

The first seat includes a first seat surface, the second seat includes a second seat surface, the first seat surface is used to cooperate with the end surface of the second body, and the second seat surface is used to cooperate with the end surface of the first body. The dimensions of first coupler and second coupler are matched, so that when the first coupler and the second coupler are combined and fastened to each other, a rectangular structure is formed.

The second guide includes a blind hole and a ridge surrounding the blind hole. The blind hole is to align with the through hole in the first guide and the ridge surrounding the blind hole is so designed to mate with the counterbore surrounding the through hole.

To reinforce the two or more first guide and second guide, one or more flanges may connect the outer walls of first guide and second guide with the wall of their respective first body and second body.

The number of first guide and second guide in first coupler and second coupler are the same and aligned with each other. In the preferred embodiment, the number of first guide and second guide are three and arranged as an isosceles triangle.

The first coupler and the second coupler are both integrally formed structures.

When compared with the prior art, the present disclosure allows for a roof support structure for two-tier gazebo roofs that is broken down into separate components, that may be assembled and disassembled without adversely affecting the firmness and endurance of the gazebo while reducing the packaging and transportation costs.

The features of the present invention can be clearly understood by referring to the drawings of the present invention and the detailed description of the preferred embodiments below.

BRIEF DESCRIPTION OF DRAWINGS

The present invention will become more fully understood from the detailed description and accompanying drawings. Other systems, methods, features, and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims. Component parts shown in the drawings are not necessarily to scale and may be exaggerated to better illustrate the important features of the invention. Dimensions disclosed or shown are exemplary only. In the drawings, like reference numerals may designate like parts throughout the different views, wherein:

FIG. 1 is the overall structure schematic diagram one of the present disclosure;

FIG. 2 is the overall structure schematic diagram two of the present disclosure;

FIG. 3 is an enlarged schematic diagram of part A in FIG. 1 ;

FIG. 4 is a schematic diagram of the upper frame having a first coupler and the lower frame having a second coupler, the first coupler and second coupler being joined together so that upper frame and lower frame become a single assembly;

FIG. 5 shows an isometric view of the first coupler and second coupler oriented so that the internal structure of first coupler is visible;

FIG. 6 shows an isometric view of the first coupler and second coupler oriented so that the internal structure of second coupler is visible;

FIG. 7 is a cross-sectional structural schematic diagram of the first coupler of the present invention:

FIG. 8 is a cross-sectional structure schematic diagram of the second coupler of the present invention; and

FIG. 9 is a schematic diagram of a secondary embodiment of the single piece version of the coupling assembly of the present invention.

Among them, central roof 1; upper frame 11; surrounding roof 2; lower frame 21; tent frame 3; coupling assembly 4; first coupler 5; first seat 51; first seat surface 511; first body 52; first guide 53; through hole 531; outer counterbore 532; inner counterbore 533; first cavity 54; second coupler 6; second seat 61; second seat surface 611; second body 62; second guide 63; blind hole 631; ridge 632; second cavity 64; support flange 65.

DETAILED DESCRIPTION OF THE INVENTION

The invention is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the invention can be practiced without these specific details. In other instances, well-known structures and devices are shown in schematic form in order to facilitate a description thereof. Various embodiments are discussed hereinafter. It should be noted that the figures are described only to facilitate the description of the embodiments. They are neither intended as an exhaustive description of the invention, nor do they limit the scope of the invention. Additionally, an illustrated embodiment need not have all the aspects or advantages shown. Thus, in other embodiments, any of the features described herein from different embodiments may be combined.

As shown in FIGS. 1 to 8 , a gazebo provided by the present invention includes tent frame 3 and a roof. The roof includes a central roof 1 in the middle and surrounding roof 2 encompassing and below central roof 1 so that a gap for venting exists between central roof 1 and surrounding roof 2. Central roof 1 and surrounding roof 2 are installed together through coupling assembly 4, specifically: central roof 1 includes a number of upper frame 11, surrounding roof 2 includes a number of lower frame 21, and a single upper frame 11 corresponds to a single lower frame 21. Lower frame 21 and upper frame 11 are mated and coupled by coupling assembly 4. According to different roof structures, the number of upper frame 11 and lower frame 21 can be three or more for a circular gazebo or four or more for a rectangular gazebo. Coupling assembly 4 includes a first coupler 5 and a second coupler 6. First coupler 5 and second coupler 6 can be releasably mated by fasteners after being combined. First coupler 5 is permanently attached to upper frame 11 and upper frame 11 supports central roof 1. Second coupler 6 is permanently attached to lower frame 21 and lower frame 21 supports surrounding roof 2.

According to the above structure, the present embodiment adopts coupling assembly 4 to realize the connection of upper frame 11 and lower frame 21, so that the frame supporting the roof's hips may be disassembled, reducing packaging and transportation costs while ensuring the firmness of the product structure and bearing capacity.

Based on the above, first coupler 5 is permanently attached to upper frame 11 while second coupler 6 is permanently attached to lower frame 21. The couplers may be permanently attached to the hip frames by welding or other means are known to those with ordinary skill in the art. Moreover, this arrangement may be altered so that first coupler 5 is permanently attached to lower frame 21 while second coupler 6 is permanently attached to upper frame 11.

Based on any one of the above-mentioned embodiments, first coupler 5 includes a first seat 51 and a first body 52. First seat 51 and first body 52 are arranged as an “L” shaped structure where the vertical portion of the “L” shaped structure comprises first body 52 and the horizontal portion of the “L” shaped structure comprises first seat 51. Within first body 52 is first cavity 54 and within first cavity 54 at least one first guide 53 is present. Second coupler 6 includes second seat 61 and second body 62. Second seat 61 and second body 62 are arranged as an “L” shaped structure where the vertical portion of the “L” shaped structure comprises second body 62 and the horizontal portion of the “L” shaped structure comprises second seat 61. Within second body 62 is second cavity 64 and within second cavity 64 at least one second guide 63 is present. The at least one first guide 53 in first cavity 54 is used to mate with the at least one second guide 63 in second cavity 64 so that first coupler 5 and second coupler 6 may be releasably fastened together thereby. As first coupler 5 and second coupler 6 are structurally inverted, when brought together a rectangular structure is formed. This is shown as coupling assembly 4 in FIGS. 3, 4, 5, and 6 . As first seat 51 includes first seat surface 511, and second seat 61 includes second seat surface 611, first seat surface 511 is used to cooperate with second distal surface 66 of second body 62, and second seat surface 611 is used to cooperate with first distal surface 55 of first body 52, so that first coupler 5 and second coupler 6 are merged resulting in a rectangular structure being formed.

In the preferred embodiment, first coupler 5 is permanently attached upper frame 11 by means of welding. Welding is also used to permanently attach second coupler 6 to lower frame 21. Other means of permanently attaching first coupler 5 to upper frame 11 and second coupler 6 to lower frame 21 are well known in the art. In the actual fixing and welding process, first proximal surface 56 is usually a plane structure, which is used for welding and fixing with the bottom surface of upper frame 11. Second proximal surface 67 adopts a V-shaped groove structure for welding with the upper end surface of lower frame 21. Usually, the upper end surface of lower frame 21 is an inverted V-shaped boss, which is used to cooperate with the V-shaped groove in second proximal surface 67 to realize welding and fixing. Configuring first proximal surface 56 and second proximal surface 67 to mate with the corresponding plane or surface of upper frame 11 and lower frame 21 facilitates the permanent attachment of first coupler 5 and second coupler 6 to upper frame 11 and lower frame 21 respectively.

Preferably, first guide 53 includes through hole 531; outer counterbore 532 located on the outer side of through hole 531 which is configured to adopt a countersunk head bolt; and inner counterbore 533 located on the inner side of through hole 531 and is configured to receive ridge 632. Second guide 63 includes blind hole 631, which may have an internal thread structure to receive a fastener, and ridge 632. Blind hole 631 is used to cooperate with and is aligned with through hole 531 so as to receive a fastener that passes within through hole 531. Ridge 632 is configured so that when first coupler 5 and second coupler 6 are joined together, ridge 632 is either fully or partially embedded in inner counterbore 533 as previously discussed. In a secondary embodiment, second guide 63 can be an insert nut, which is convenient for installation with first guide 53, and can also be directly provided with a lock hole and other structures.

In the specific installation process, after first coupler 5 and second coupler 6 are mated, a fastener, preferably a screw, is inserted into first coupler 5 passing through, in sequence, outer counterbore 532, through hole 531, and inner counterbore 533 and then into blind hole 631 of second coupler 6 to complete the mating process. As each one or more rust guide 53 of first coupler 5 is aligned with and designed to mate to each one or more second guide 63 of second coupler 6, the mating of first coupler 5 and second coupler 6 is simplified, improving the assembly and joining of upper frame 11 and lower frame 21.

In the preferred embodiment, in order to strengthen the mating of first coupler 5 with second coupler 6, the thickness dimension of second body 62 in second coupler 6 is generally larger than the thickness dimension of first body 52 in first coupler 5. The purpose here being to increase the depth of blind hole 631, thereby increasing the threaded tightness of the fastener.

In a secondary embodiment, the structure of blind hole 631 in second guide 63 can be changed to a through hole structure, and a third counterbore is provided on the outer surface of second guide 63. In this embodiment, a fastener penetrates both first guide 53 and second guide 63. First guide 53 and second guide 63 are then mated by threading a nut onto the portion of the fastener extending from second guide 63. The nut may further be embedded in the third counterbore at the same time.

In yet another embodiment, the structural strength of second coupler 6 is enhanced by joining each of the one or more second guide 63 with one or more of the walls surrounding second cavity 64 by using one or more support flange 65. The one or more support flange 65 about each of the one or more second guide 63 will improve the structural life of second coupler 6 while minimizing the weight of second coupler 6.

In the preferred embodiment, there are three first guide 53 aligned to and designed to mate with three second guide 63. The three first guide 53 and three second guide 63 are arranged triangularly, that is each first guide 53 and each second guide 63 form the points of the triangle. This design improves the overall strength of the mating of first coupler 5 and each second coupler 6.

In the preferred embodiment, first coupler 5 and second coupler 6 are both integrally formed structures, which are usually cast aluminum integral casting, or aluminum casting integral forming, etc., which can ensure the overall strength of the product.

This disclosure reveals a novel coupling assembly that may be utilized to join a upper frame and a lower frame of a two tier roof used on an outdoor sunshade. By this novel design, the upper frame and the lower frame of a two tier roof used on an outdoor sunshade may be shipped as separate components. As a result, the packaging and transportation costs are reduced while the firmness and bearing capacity of an outdoor sunshade are ensured at the same time.

FIG. 9 shows a schematic diagram of a secondary embodiment of the coupling assembly of the present invention. In this embodiment coupling assembly 4 is comprised of a single component that may be releasably attached to both upper frame 11 and lower frame 21. In this embodiment, coupling assembly 4 consists of a single rectangular block having an upper plate and a lower plate that are permanently affixed to the rectangular block. The upper and lower plates have one or more through holes that align to one or more threaded blind holes on both upper frame 11 and lower frame 21. Screw fasteners may then be inserted through the through holes in both the upper and lower plates found on coupling assembly 4 and into the aligned blind holes found on both upper frame 11 and lower frame 21 to releasably attach coupling assembly 4 to both upper frame 11 and lower frame 21. In this manner forming a single piece consisting of upper frame 11, lower frame 21, and coupling assembly 4.

In yet another embodiment, coupling assembly 4 may be permanently attached to either upper frame 11 or lower frame 21 and then releasably attached to the opposing frame. In this embodiment, coupling assembly 4 consists of a single rectangular block, as shown in FIG. 9 , but one end is permanently attached to either upper frame 11 or lower frame 21 and the opposing end having a plate containing one or more through holes. These through holes align to one or more threaded blind holes on the frame that coupling assembly 4 is to releasably attach to. Screw fasteners may then be inserted through the through holes in the plate found on coupling assembly 4 and into the aligned blind holes found on the frame, either upper frame 11 or lower frame 21, that coupling assembly 4 is to releasably attach to thereby forming a single piece consisting of upper frame 11, lower frame 21, and coupling assembly 4.

Exemplary embodiments of the invention have been disclosed in an illustrative style. Accordingly, the terminology employed throughout should be read in a non-limiting manner. Although minor modifications to the teachings herein will occur to those well versed in the art, it shall be understood that what is intended to be circumscribed within the scope of the patent warranted hereon are all such embodiments that reasonably fall within the scope of the advancement to the art hereby contributed and that that scope shall not be restricted, except in the light of the appended claims and their equivalents. 

What is claimed is:
 1. An outdoor sunshade comprising: a roof, the roof further comprising: a central roof positioned in the center of said roof; and a surrounding roof encompassing and below said central roof such that a vertical gap exists between said central roof and said surrounding roof; an upper frame supporting said central roof; a lower frame supporting said surrounding roof; a first coupler attached to said upper frame; and a second coupler attached to said lower frame; wherein said first coupler and said second coupler are releasably fastenable to each other thereby causing said upper frame and said lower frame to be attached to each other.
 2. The outdoor sunshade of claim 1 wherein said first coupler is attached to said upper frame and said second coupler is attached to said lower frame by welding.
 3. The outdoor sunshade of claim 1 wherein the cross section of said first coupler is in the shape of an “L” where the vertical portion of the “L” defines a first body; the horizontal portion of the “L” defines a first seat; the top of the horizontal portion of the “L” defines a first seat surface; and the top of the vertical portion of the “L” defines a first distal surface; and the cross section of said second coupler is in the shape of an “L” where: the vertical portion of the “L” defines a second body; the horizontal portion of the “L” defines a second seat; the top of the horizontal portion of the “L” defines a second seat surface; and the top of the vertical portion of the “L” defines a second distal surface.
 4. The outdoor sunshade of claim 3 wherein said first body further comprises one or more first guides, said first guide comprising a through hole, and said second body further comprises one or more second guides, said second guide comprising a blind hole.
 5. The outdoor sunshade of claim 4 wherein the one or more said first guides and the one or more said second guides are aligned with each other.
 6. The outdoor sunshade of claim 3 wherein said first seat surface cooperates with said second distal surface and said second seat surface cooperates with said first distal surface so that when said first coupler is fastened to said second coupler a rectangular structure is formed.
 7. The outdoor sunshade of claim 4 wherein the one or more said second guides are supported by one or more support flanges.
 8. The outdoor sunshade of claim 4 wherein the number of said first guides are three, the number of second guides are three, said first guides and said second guides are arranged in an isosceles triangle.
 9. The outdoor sunshade of claim 1 wherein said first coupler and said second coupler are integrally formed.
 10. An outdoor sunshade comprising: a roof, the roof further comprising: a central roof positioned in the center of said roof; and a surrounding roof encompassing and below said central roof such that a vertical gap exists between said central roof and said surrounding roof; an upper frame supporting said central roof; a lower frame supporting said surrounding roof, said lower frame having one or more blind holes; and a coupling assembly attached to said upper frame, said coupling assembly further comprising: a rectangular block with a first surface being attached to said upper frame; and a plate attached to the surface opposing said first surface, said plate having one or more through holes; wherein one or more fasteners may pass through said through holes and into aligned said blind holes so that said upper frame may be releasably fastenable to said lower frame.
 11. An outdoor sunshade comprising: a roof, the roof further comprising: a central roof positioned in the center of said roof; and a surrounding roof encompassing and below said central roof such that a vertical gap exists between said central roof and said surrounding roof; an upper frame supporting said central roof, said upper frame having one or more blind holes; a lower frame supporting said surrounding roof; and a coupling assembly attached to said lower frame, said coupling assembly further comprising: a rectangular block with a first surface being attached to said lower frame; and a plate attached to the surface opposing said first surface, said plate having one or more through holes; wherein one or more fasteners may pass through said through holes and into aligned said blind holes so that said lower frame may be releasably fastenable to said upper frame.
 12. An outdoor sunshade comprising: a roof, the roof further comprising: a central roof positioned in the center of said roof; and a surrounding roof encompassing and below said central roof such that a vertical gap exists between said central roof and said surrounding roof; an upper frame supporting said central roof, said upper frame having one or more blind holes; a lower frame supporting said surrounding roof, said lower frame having one or more blind holes; a coupling assembly further comprising: a rectangular block with a first surface and a second surface opposite said first surface; a first plate attached to said first surface said first plate having one or more through holes; and a second plate attached to said second surface said second plate having one or more through holes; wherein one or more fasteners may pass through said through holes of said coupling assembly and into aligned said blind holes of said upper frame and lower frame so that said upper frame may be releasably fastened together with said lower frame. 